US20180171118A1 - Rubber composition - Google Patents

Rubber composition Download PDF

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Publication number
US20180171118A1
US20180171118A1 US15/693,627 US201715693627A US2018171118A1 US 20180171118 A1 US20180171118 A1 US 20180171118A1 US 201715693627 A US201715693627 A US 201715693627A US 2018171118 A1 US2018171118 A1 US 2018171118A1
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Prior art keywords
rubber
mass
parts
amount
rubber composition
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US15/693,627
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Takashi Yuri
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Toyo Tire Corp
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Toyo Tire and Rubber Co Ltd
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Assigned to TOYO TIRE & RUBBER CO., LTD. reassignment TOYO TIRE & RUBBER CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: YURI, TAKASHI
Publication of US20180171118A1 publication Critical patent/US20180171118A1/en
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L9/00Compositions of homopolymers or copolymers of conjugated diene hydrocarbons
    • C08L9/06Copolymers with styrene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L53/00Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L53/02Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
    • C08L53/025Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes modified
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L15/00Compositions of rubber derivatives
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/02Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/02Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/03Polymer mixtures characterised by other features containing three or more polymers in a blend
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/03Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C08L2205/035Polymer mixtures characterised by other features containing three or more polymers in a blend containing four or more polymers in a blend
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00Properties characterising the ingredient of the composition
    • C08L2207/32Properties characterising the ingredient of the composition containing low molecular weight liquid component
    • C08L2207/324Liquid component is low molecular weight polymer

Definitions

  • the present invention relates to a rubber composition useful as a raw material for producing vulcanized rubbers improved in wet performance, abrasion resistance, and fuel efficiency with a good balance.
  • Tires are generally used in various running environments, and are required to be improved in, e.g., wet performance, which is such a performance that the tires grip a wet road surface in rain.
  • wet performance which is such a performance that the tires grip a wet road surface in rain.
  • the resultant vulcanized rubber may be deteriorated in abrasion resistance and fuel efficiency.
  • a technique for improving these properties with a good balance has been required.
  • Patent Document 1 listed below describes a technique of blending, into a rubber composition for treads, at least one kind of diene elastomer, and a hydrogenated styrene thermoplastic elastomer in an amount of 18 to 40 parts by mass for 100 parts by mass of the diene elastomer to develop a tire tread showing a low rolling resistance and keeping a good wet gripping performance.
  • Patent Document 2 listed below describes a technique of blending, into a rubber composition, a diene rubber, and an elastomer yielded by hydrogenating a styrene-diene-styrene copolymer partially to provide a rubber composition for tire treads that is improved in steering stability, dry performance and wet performance up to a level higher than a conventional level.
  • Patent Document 3 listed below describes a technique of blending a hydrogenated styrene based thermoplastic elastomer into a rubber composition to provide a tread rubber composition for high-performance tires that is able to improve the tires in initial gripping performance, gripping performance and durability with a good balance.
  • Patent Document 4 listed below describes a technique of blending, into a rubber composition, styrene butadiene rubber and a hydrogenated styrene based thermoplastic elastomer to provide a tread rubber composition for high-performance wet tires that is able to improve the tires in initial gripping performance and gripping performance on a wet road surface, and in gripping performance on a dry-up road surface and abrasion resistance.
  • Patent Document 1 Japanese Patent No. 5687281
  • Patent Document 2 JP-A-2014-189698
  • Patent Document 3 JP-A-2015-110703
  • Patent Document 4 JP-A-2015-110704
  • the present invention has been made, and an object thereof is to provide a rubber composition making it possible that when the composition is made into a vulcanized rubber, the rubber is improved in wet performance, abrasion resistance, and fuel efficiency with a good balance.
  • the object can be attained by the present invention, which relates to a rubber composition including a terminal-modified polystyrene butadiene rubber (referred to also as a “terminal-modified SBR” hereinafter) in an amount of 10 to 80 parts by mass when the entire amount of rubber components in the composition is regarded as 100 parts by mass; and a thermoplastic elastomer in an amount of 1 to 20 parts by mass for the 100 parts by mass of the rubber components.
  • This thermoplastic elastomer shows a tan ⁇ peak value in the range of ⁇ 20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, and the peak value is 1 or more.
  • the specified amount of the rubber components is constituted by the terminal-modified SBR, and further the composition includes the thermoplastic elastomer, which shows a tan ⁇ peak in the specified temperature range; thus, a vulcanized rubber obtained from the composition can be improved in wet property. Furthermore, in the resultant vulcanized rubber, the thermoplastic elastomer forms a phase containing no filler such as carbon black or silica (filler absent phase) so that the vulcanized rubber is relieved in stress concentration so as to be improved in abrasion resistance and fuel efficiency.
  • the rubber composition according to the present invention includes, particularly, silica as a filler, the silica is improved in dispersibility in the composition to improve the vulcanized rubber in wet performance.
  • the rubber composition preferably further includes, as one or more of the rubber components, at least one of natural rubber (referred to also as “NR” hereinafter) and polybutadiene rubber (referred to also as “BR” hereinafter).
  • NR natural rubber
  • BR polybutadiene rubber
  • the rubber composition includes, as the rubber component(s), NR and/or BR in addition to the terminal-modified SBR, the vulcanized rubber can be favorably improved in wet performance, abrasion resistance, and fuel efficiency with a better balance.
  • the rubber composition preferably further includes a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass, and preferably further includes a liquid rubber having a Tg of ⁇ 40° C. or lower in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass.
  • a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass
  • a liquid rubber having a Tg of ⁇ 40° C. or lower in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass.
  • the rubber composition according to the present invention includes, as one of its rubber components, a terminal-modified SBR in an amount in a specified range, and further includes a specified thermoplastic elastomer.
  • a terminal-modified SBR in an amount in a specified range
  • a specified thermoplastic elastomer included in the entire amount of the rubber components.
  • the rubber composition according to the present invention may include, as another or others of the rubber components, one or more rubber components other than the terminal-modified SBR.
  • the resultant vulcanized rubber can be favorably improved in wet performance, abrasion resistance, and fuel efficiency with a better balance.
  • a diene rubber that is other than NR and BR and that may be included in the composition include polyisoprene rubber (IR), chloroprene rubber (CR), and nitrile rubber (NBR).
  • IR polyisoprene rubber
  • CR chloroprene rubber
  • NBR nitrile rubber
  • a rubber yielded by modifying a rubber as described above to give a desired property to the rubber is preferably usable.
  • the rubber composition according to the present invention includes a specified thermoplastic elastomer in an amount from 1 to 20 parts by mass, preferably from 1 to 15 parts by mass for the entire amount of the rubber components when this entire amount is regarded as 100 parts by mass.
  • This thermoplastic elastomer is specifically a thermoplastic elastomer showing a tan ⁇ peak value in the range of ⁇ 20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, the peak value being 1 or more.
  • the thermoplastic elastomer is in particular preferably a styrene based thermoplastic elastomer.
  • thermoplastic elastomer a thermoplastic elastomer having a functional group that can react with or interact with a filler which may be blended into the rubber composition
  • the resultant vulcanized rubber is favorably improved in, particularly, fatigue resistance.
  • the functional group include a hydroxyl group, an amino group, a carboxyl group, maleic anhydride, a silanol group, an alkoxysilyl group, an epoxy group, a glycidyl group, polyether, and polysiloxane.
  • silica and/or carbon black which will be described below as examples of the filler, has/have many functional groups such as hydroxyl, carboxyl, and silanol groups, so that the functional groups react with or interact with functional groups which the thermoplastic elastomer has, thereby improving the filler in dispersibility in the composition.
  • the rubber composition according to the present invention may further include a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount preferably from 1 to 40 parts by mass, more preferably from 1 to 25 parts by mass for the entire amount of the rubber components when this entire amount is regarded as 100 parts by mass.
  • a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount preferably from 1 to 40 parts by mass, more preferably from 1 to 25 parts by mass for the entire amount of the rubber components when this entire amount is regarded as 100 parts by mass.
  • the rubber composition according to the present invention further include a liquid rubber since a further improvement is made not only in the workability of the rubber composition but also in the wet performance and the abrasion resistance of a tire of the resultant vulcanized rubber.
  • the liquid rubber has fluidity, and is made of chain molecules which each have a molecular weight of several thousands, and which may undergo crosslinkage or chain-extending reaction to turn to a rubber elastic body.
  • the liquid rubber preferably has, at terminals of molecules thereof, amino, hydroxy, carboxy, isocyanate or thiol groups, or halogen radicals, or such functional groups or radicals.
  • the liquid rubber is, for example, a diene rubber type (1,2-BR, 1,4-BR, 1,4-IR, SBR, NBR, CR or IIR), silicone rubber type, urethane rubber type or polysulfide rubber type liquid rubber.
  • the blend amount of the liquid rubber in the rubber composition is preferably from 1 to 40 parts by mass, more preferably from 1 to 25 parts by mass for the entire amount of the rubber components when the entire amount is regarded as 100 parts by mass.
  • the rubber composition according to the present invention preferably includes silica as a filler.
  • the species of the silica may be a species usable for ordinary rubber-reinforcement, such as wet silica, dry silica, sol-gel silica or surface-treated silica. Out of these species, wet silica is preferred.
  • the blend amount of the silica is preferably from 20 to 120 parts by mass, more preferably from 40 to 100 parts by mass for the entire amount of the rubber components when the entire amount is regarded as 100 parts by mass.
  • the rubber composition of the present invention may include a silane coupling agent.
  • the silane coupling agent is not particularly limited as far as the agent is a silane coupling agent containing, in the molecule thereof, sulfur.
  • various silane coupling agents are usable which are each blended together with silica.
  • Examples thereof include sulfide silanes such as bis(3-triethoxysilylpropyl) tetrasulfide (for example, “Si69” manufactured by Degussa AG), bis(3-triethoxysilylpropyl) disulfide (for example, “Si75” manufactured by Degussa AG), bis(2-triethoxysilylethyl) tetrasulfide, bis(4-triethoxysilylbutyl) disulfide, bis(3-trimethoxysilylpropyl) tetrasulfide, and bis(2-trimethoxysilylethyl) disulfide; mercaptosilanes such as ⁇ -mercaptopropyltrimethoxysilane, ⁇ -mercaptopropyltriethoxysilane, mercaptopropylmethyldimethoxysilane, mercaptopropyldimethylmethoxysilane
  • the rubber composition may contain carbon black as a filler.
  • the species of the carbon black may be any carbon black species used in an ordinary rubber industry, such as SAF, ISAF, HAF, FEF or GPF, or may be an electroconductive carbon black species such as acetylene black or ketjen black.
  • the carbon black is blended into the rubber composition according to the present invention in an amount preferably from 1 to 70 parts by mass, more preferably from 5 to 60 parts by mass for 100 parts by mass of the diene rubbers.
  • thermoplastic elastomer In addition to the diene rubbers, specified thermoplastic elastomer, tackifying resin, liquid rubber, carbon black, silica and silane coupling agent each detailed above, the following may be blended into the rubber composition according to the present invention: vulcanization blending agents, an antiaging agent, zinc oxide, stearic acid, softeners such as wax and oil, a processing aid, and others.
  • the antiaging agent may be an antiaging agent used ordinarily for rubbers, examples thereof including aromatic amine type, amine-ketone type, monophenolic type, bisphenolic type, polyphenolic type, dithiocarbamate type, and thiourea type antiaging agents. Such antiaging agents may be used singly or in the form of an appropriate mixture of two or more thereof.
  • the antiaging agent content is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components.
  • vulcanization blending agents examples include vulcanizing agents such as sulfur and organic peroxides, a vulcanization accelerator, a vulcanization accelerator aid, and a vulcanization retardant.
  • the species of sulfur as one of the vulcanization blending agents may be any ordinary sulfur species for rubbers. Examples thereof include powdery sulfur, precipitated sulfur, insoluble sulfur, and highly dispersible sulfur. When physical properties, the durability and others of the resultant vulcanized rubber are considered, the blend amount of the sulfur is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components, the amount being in terms of the sulfur content.
  • the vulcanization accelerator may be a vulcanization accelerator used ordinarily for rubber-vulcanization. Examples thereof include sulfenamide type, thiuram type, thiazole type, thiourea type, guanidine type, and dithiocarbamate type vulcanization accelerators. Such vulcanization accelerators may be used singly or in the form of an appropriate mixture of two or more thereof.
  • the blend amount of the vulcanization accelerator(s) is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components.
  • the rubber composition according to the present invention can be yielded by using a kneading machine used in an ordinary rubber industry, such as a Banbury mixer, a kneader or a roll, to mix/knead the diene rubbers, specified thermoplastic elastomer, tackifying resin, liquid rubber, carbon black, silica and silane coupling agent each detailed above, and components that may be optionally used, which are carbon black, vulcanization blending agents, an antiaging agent, zinc oxide, stearic acid, softeners such as wax and oil, a processing aid and others.
  • a kneading machine used in an ordinary rubber industry, such as a Banbury mixer, a kneader or a roll, to mix/knead the diene rubbers, specified thermoplastic elastomer, tackifying resin, liquid rubber, carbon black, silica and silane coupling agent each detailed above, and components that may be optionally used, which are
  • the method for blending each component with each other is not particularly limited, and may be, for example, a method of mixing/kneading, in advance, blending components other than the vulcanization blending agents such as the sulfur-containing vulcanizing agent and the vulcanization accelerator to prepare a masterbatch, adding the remaining components thereto, and further mixing/kneading the entire components; a method of adding each component in any order, and then mixing/kneading the components; or a method of adding the entire components simultaneously and mixing/kneading the components.
  • a method of mixing/kneading in advance, blending components other than the vulcanization blending agents such as the sulfur-containing vulcanizing agent and the vulcanization accelerator to prepare a masterbatch, adding the remaining components thereto, and further mixing/kneading the entire components; a method of adding each component in any order, and then mixing/kneading the components; or a method of adding the entire components
  • a viscoelasticity tester manufactured by Toyo Seiki Seisaku-sho, Ltd. is used to measure the loss tangent tan ⁇ of one of the samples of each of the above-mentioned examples at a frequency of 10 Hz, a static strain of 10%, a dynamic strain of 1% and a temperature of 0° C. About each of the examples, the measured value is evaluated as an index relative to the value of Comparative Example 1, this value being regarded as 100. It is meant that as the resultant numerical value is larger, the rubber composition is better in wet performance.
  • a viscoelasticity tester manufactured by Toyo Seiki Seisaku-sho, Ltd. is used to measure the loss tangent tan ⁇ of one of the samples of each of the above-mentioned examples at a frequency of 10 Hz, a static strain of 10%, a dynamic strain of 1% and a temperature of 60° C. About each of the examples, the measured value is evaluated as an index relative to the value of Comparative Example 1, this value being regarded as 100. It is meant that as the resultant numerical value is smaller, the rubber composition is better in low exothermicity.
  • a Lambourn abrasion tester manufactured by Iwamoto Seisaku-sho Co., Ltd. is used to measure the abrasion loss of one of the samples of each of the above-mentioned examples at a load of 40 N, and a slip ratio of 30% in accordance with JIS K6264.
  • the result is represented as the inverse number of an index relative to the value of Comparative Example 1, this value being regarded as 100. It is demonstrated that as the resultant numerical value is larger, the rubber composition is better in abrasion resistance.
  • a rubber composition of each of Examples 1 to 8 and Comparative Examples 1 to 5 was formulated, and then kneaded by using an ordinary Banbury mixer to prepare a rubber composition.
  • the blending agents shown in Table 1 are as follows (in Table 1, the blend amount of each of the blending agents is represented as a numerical value (in the unit of parts by mass) that is relative to 100 parts by mass of rubber components).
  • Terminal-non-modified SBR “VSL 5025-0HM”, manufactured by Lanxess AG
  • Terminal-modified SBR “HPR 350”, manufactured by JSR Corporation
  • BR “BR 150B”, manufactured by Ube Industries, Ltd.;
  • Tackifying Resin 1 “FTR 6125” manufactured by Mitsui Chemicals, Inc. (copolymer made from a styrene based monomer and an aliphatic monomer; softening point: 125° C., and molecular weight: 1950)
  • Tackifying Resin 2 “FMR 0150” manufactured by Mitsui Chemicals, Inc. (copolymer made from a styrene based monomer and indene; softening point: 145° C., and molecular weight: 1190)
  • Tackifying Resin 3 “NITTO RESING90” manufactured by Nitto Chemical Co., Ltd. (coumarone resin; softening point: 90° C., and molecular weight: 770)
  • Zinc flower “Zinc flower No. 1” (manufactured by Mitsui Mining & Smelting Co., Ltd.)
  • Antiaging agent “ANTIGEN 6C”, manufactured by Sumitomo Chemical Co., Ltd.
  • Stearic acid “LUNAC S-20” (manufactured by Kao Corporation)
  • Wax “OZOACE 0355” (manufactured by Nippon Seiro Co., Ltd.)
  • Sulfur “5%-Oil-blended powdery sulfur” (manufactured by Tsurumi Chemical Industry Co., Ltd.)
  • Vulcanization accelerators Vulcanization accelerators:
  • Vulcanization accelerator 1 “SOXINOL CZ” (manufactured by Sumitomo Chemical Co., Ltd.), and
  • Vulcanization accelerator 2 “NOCCELER D”, manufactured by Ouchi Shinko Chemical Industrial Co., Ltd.;
  • Liquid rubber 1 “LBR 307” manufactured by Kuraray Co., Ltd. (liquid polybutadiene; Tg: ⁇ 95° C.), and
  • Liquid rubber 2 “LIR 30” manufactured by Kuraray Co., Ltd. (liquid polyisoprene; Tg: ⁇ 63° C.)

Abstract

A rubber composition, comprising a terminal-modified polystyrene butadiene rubber in an amount of 10 to 80 parts by mass when the entire amount of rubber components in the composition is regarded as 100 parts by mass; and a thermoplastic elastomer in an amount of 1 to 20 parts by mass for the 100 parts by mass of the rubber components; the thermoplastic elastomer showing a tan δ peak value in the range of −20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, and the peak value being 1 or more.

Description

    BACKGROUND OF THE INVENTION Field of the Invention
  • The present invention relates to a rubber composition useful as a raw material for producing vulcanized rubbers improved in wet performance, abrasion resistance, and fuel efficiency with a good balance.
  • Description of the Related Art
  • Tires are generally used in various running environments, and are required to be improved in, e.g., wet performance, which is such a performance that the tires grip a wet road surface in rain. However, in the case of designing the blend of a rubber composition to improve the wet performance, the resultant vulcanized rubber may be deteriorated in abrasion resistance and fuel efficiency. Thus, a technique for improving these properties with a good balance has been required.
  • Patent Document 1 listed below describes a technique of blending, into a rubber composition for treads, at least one kind of diene elastomer, and a hydrogenated styrene thermoplastic elastomer in an amount of 18 to 40 parts by mass for 100 parts by mass of the diene elastomer to develop a tire tread showing a low rolling resistance and keeping a good wet gripping performance.
  • Patent Document 2 listed below describes a technique of blending, into a rubber composition, a diene rubber, and an elastomer yielded by hydrogenating a styrene-diene-styrene copolymer partially to provide a rubber composition for tire treads that is improved in steering stability, dry performance and wet performance up to a level higher than a conventional level.
  • Patent Document 3 listed below describes a technique of blending a hydrogenated styrene based thermoplastic elastomer into a rubber composition to provide a tread rubber composition for high-performance tires that is able to improve the tires in initial gripping performance, gripping performance and durability with a good balance.
  • Furthermore, Patent Document 4 listed below describes a technique of blending, into a rubber composition, styrene butadiene rubber and a hydrogenated styrene based thermoplastic elastomer to provide a tread rubber composition for high-performance wet tires that is able to improve the tires in initial gripping performance and gripping performance on a wet road surface, and in gripping performance on a dry-up road surface and abrasion resistance.
  • PRIOR ART DOCUMENTS Patent Documents
  • Patent Document 1: Japanese Patent No. 5687281
  • Patent Document 2: JP-A-2014-189698
  • Patent Document 3: JP-A-2015-110703
  • Patent Document 4: JP-A-2015-110704
  • However, the present inventors have made eager investigations to find that when the rubber composition of each of the above-mentioned precedent techniques is made into a tire, there remains, in the techniques, a room to be further improved for an improvement of the tire in wet performance, abrasion resistance, and fuel efficiency with a good balance.
  • SUMMARY OF THE INVENTION
  • In the light of the actual situation, the present invention has been made, and an object thereof is to provide a rubber composition making it possible that when the composition is made into a vulcanized rubber, the rubber is improved in wet performance, abrasion resistance, and fuel efficiency with a good balance.
  • The object can be attained by the present invention, which relates to a rubber composition including a terminal-modified polystyrene butadiene rubber (referred to also as a “terminal-modified SBR” hereinafter) in an amount of 10 to 80 parts by mass when the entire amount of rubber components in the composition is regarded as 100 parts by mass; and a thermoplastic elastomer in an amount of 1 to 20 parts by mass for the 100 parts by mass of the rubber components. This thermoplastic elastomer shows a tan δ peak value in the range of −20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, and the peak value is 1 or more. In the rubber composition according to the present invention, the specified amount of the rubber components is constituted by the terminal-modified SBR, and further the composition includes the thermoplastic elastomer, which shows a tan δ peak in the specified temperature range; thus, a vulcanized rubber obtained from the composition can be improved in wet property. Furthermore, in the resultant vulcanized rubber, the thermoplastic elastomer forms a phase containing no filler such as carbon black or silica (filler absent phase) so that the vulcanized rubber is relieved in stress concentration so as to be improved in abrasion resistance and fuel efficiency. When the rubber composition according to the present invention includes, particularly, silica as a filler, the silica is improved in dispersibility in the composition to improve the vulcanized rubber in wet performance.
  • The rubber composition preferably further includes, as one or more of the rubber components, at least one of natural rubber (referred to also as “NR” hereinafter) and polybutadiene rubber (referred to also as “BR” hereinafter). When the rubber composition includes, as the rubber component(s), NR and/or BR in addition to the terminal-modified SBR, the vulcanized rubber can be favorably improved in wet performance, abrasion resistance, and fuel efficiency with a better balance.
  • The rubber composition preferably further includes a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass, and preferably further includes a liquid rubber having a Tg of −40° C. or lower in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass. These embodiments can further improve the vulcanized rubber in wet performance.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • The rubber composition according to the present invention includes, as one of its rubber components, a terminal-modified SBR in an amount in a specified range, and further includes a specified thermoplastic elastomer. When the entire amount of the rubber components is regarded as 100 parts by mass, the content of the terminal-modified SBR is from 10 to 80 parts by mass, preferably from 20 to 70 parts by mass.
  • The rubber composition according to the present invention may include, as another or others of the rubber components, one or more rubber components other than the terminal-modified SBR. When the rubber composition includes, particularly, NR and/or BR, the resultant vulcanized rubber can be favorably improved in wet performance, abrasion resistance, and fuel efficiency with a better balance. Examples of a diene rubber that is other than NR and BR and that may be included in the composition include polyisoprene rubber (IR), chloroprene rubber (CR), and nitrile rubber (NBR). As necessary, a rubber yielded by modifying a rubber as described above to give a desired property to the rubber (for example, modified NR) is preferably usable.
  • The rubber composition according to the present invention includes a specified thermoplastic elastomer in an amount from 1 to 20 parts by mass, preferably from 1 to 15 parts by mass for the entire amount of the rubber components when this entire amount is regarded as 100 parts by mass. This thermoplastic elastomer is specifically a thermoplastic elastomer showing a tan δ peak value in the range of −20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, the peak value being 1 or more. The thermoplastic elastomer is in particular preferably a styrene based thermoplastic elastomer.
  • In the case of using, as the thermoplastic elastomer, a thermoplastic elastomer having a functional group that can react with or interact with a filler which may be blended into the rubber composition, the resultant vulcanized rubber is favorably improved in, particularly, fatigue resistance. Examples of the functional group include a hydroxyl group, an amino group, a carboxyl group, maleic anhydride, a silanol group, an alkoxysilyl group, an epoxy group, a glycidyl group, polyether, and polysiloxane. A reason why the use produces the advantageous effect would be that silica and/or carbon black, which will be described below as examples of the filler, has/have many functional groups such as hydroxyl, carboxyl, and silanol groups, so that the functional groups react with or interact with functional groups which the thermoplastic elastomer has, thereby improving the filler in dispersibility in the composition.
  • The rubber composition according to the present invention may further include a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount preferably from 1 to 40 parts by mass, more preferably from 1 to 25 parts by mass for the entire amount of the rubber components when this entire amount is regarded as 100 parts by mass.
  • It is preferred that the rubber composition according to the present invention further include a liquid rubber since a further improvement is made not only in the workability of the rubber composition but also in the wet performance and the abrasion resistance of a tire of the resultant vulcanized rubber. The liquid rubber has fluidity, and is made of chain molecules which each have a molecular weight of several thousands, and which may undergo crosslinkage or chain-extending reaction to turn to a rubber elastic body. The liquid rubber preferably has, at terminals of molecules thereof, amino, hydroxy, carboxy, isocyanate or thiol groups, or halogen radicals, or such functional groups or radicals. The liquid rubber is, for example, a diene rubber type (1,2-BR, 1,4-BR, 1,4-IR, SBR, NBR, CR or IIR), silicone rubber type, urethane rubber type or polysulfide rubber type liquid rubber. The blend amount of the liquid rubber in the rubber composition is preferably from 1 to 40 parts by mass, more preferably from 1 to 25 parts by mass for the entire amount of the rubber components when the entire amount is regarded as 100 parts by mass.
  • The rubber composition according to the present invention preferably includes silica as a filler. The species of the silica may be a species usable for ordinary rubber-reinforcement, such as wet silica, dry silica, sol-gel silica or surface-treated silica. Out of these species, wet silica is preferred. The blend amount of the silica is preferably from 20 to 120 parts by mass, more preferably from 40 to 100 parts by mass for the entire amount of the rubber components when the entire amount is regarded as 100 parts by mass.
  • The rubber composition of the present invention may include a silane coupling agent. The silane coupling agent is not particularly limited as far as the agent is a silane coupling agent containing, in the molecule thereof, sulfur. In the rubber composition, various silane coupling agents are usable which are each blended together with silica. Examples thereof include sulfide silanes such as bis(3-triethoxysilylpropyl) tetrasulfide (for example, “Si69” manufactured by Degussa AG), bis(3-triethoxysilylpropyl) disulfide (for example, “Si75” manufactured by Degussa AG), bis(2-triethoxysilylethyl) tetrasulfide, bis(4-triethoxysilylbutyl) disulfide, bis(3-trimethoxysilylpropyl) tetrasulfide, and bis(2-trimethoxysilylethyl) disulfide; mercaptosilanes such as γ-mercaptopropyltrimethoxysilane, γ-mercaptopropyltriethoxysilane, mercaptopropylmethyldimethoxysilane, mercaptopropyldimethylmethoxysilane, and mercaptoethyltriethoxysilane; and protected mercaptosilanes such as 3-octanoylthio-1-propyltriethoxysilane, and 3-propionylthiopropyltrimethoxysilane. The blend amount of the silane coupling agent is preferably form 1 to 20 parts by mass, more preferably from 5 to 15 parts by mass for 100 parts by mass of the silica.
  • The rubber composition may contain carbon black as a filler. The species of the carbon black may be any carbon black species used in an ordinary rubber industry, such as SAF, ISAF, HAF, FEF or GPF, or may be an electroconductive carbon black species such as acetylene black or ketjen black. The carbon black is blended into the rubber composition according to the present invention in an amount preferably from 1 to 70 parts by mass, more preferably from 5 to 60 parts by mass for 100 parts by mass of the diene rubbers.
  • In addition to the diene rubbers, specified thermoplastic elastomer, tackifying resin, liquid rubber, carbon black, silica and silane coupling agent each detailed above, the following may be blended into the rubber composition according to the present invention: vulcanization blending agents, an antiaging agent, zinc oxide, stearic acid, softeners such as wax and oil, a processing aid, and others.
  • The antiaging agent may be an antiaging agent used ordinarily for rubbers, examples thereof including aromatic amine type, amine-ketone type, monophenolic type, bisphenolic type, polyphenolic type, dithiocarbamate type, and thiourea type antiaging agents. Such antiaging agents may be used singly or in the form of an appropriate mixture of two or more thereof. The antiaging agent content is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components.
  • Examples of the vulcanization blending agents include vulcanizing agents such as sulfur and organic peroxides, a vulcanization accelerator, a vulcanization accelerator aid, and a vulcanization retardant.
  • The species of sulfur as one of the vulcanization blending agents may be any ordinary sulfur species for rubbers. Examples thereof include powdery sulfur, precipitated sulfur, insoluble sulfur, and highly dispersible sulfur. When physical properties, the durability and others of the resultant vulcanized rubber are considered, the blend amount of the sulfur is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components, the amount being in terms of the sulfur content.
  • The vulcanization accelerator may be a vulcanization accelerator used ordinarily for rubber-vulcanization. Examples thereof include sulfenamide type, thiuram type, thiazole type, thiourea type, guanidine type, and dithiocarbamate type vulcanization accelerators. Such vulcanization accelerators may be used singly or in the form of an appropriate mixture of two or more thereof. The blend amount of the vulcanization accelerator(s) is preferably from 0.1 to 20 parts by mass for 100 parts by mass of the rubber components.
  • The rubber composition according to the present invention can be yielded by using a kneading machine used in an ordinary rubber industry, such as a Banbury mixer, a kneader or a roll, to mix/knead the diene rubbers, specified thermoplastic elastomer, tackifying resin, liquid rubber, carbon black, silica and silane coupling agent each detailed above, and components that may be optionally used, which are carbon black, vulcanization blending agents, an antiaging agent, zinc oxide, stearic acid, softeners such as wax and oil, a processing aid and others.
  • The method for blending each component with each other is not particularly limited, and may be, for example, a method of mixing/kneading, in advance, blending components other than the vulcanization blending agents such as the sulfur-containing vulcanizing agent and the vulcanization accelerator to prepare a masterbatch, adding the remaining components thereto, and further mixing/kneading the entire components; a method of adding each component in any order, and then mixing/kneading the components; or a method of adding the entire components simultaneously and mixing/kneading the components.
  • Examples
  • Hereinafter, a description will be made about examples demonstrating the subject matter and the advantageous effects of the present invention specifically, and others. In evaluating-items in the examples, and comparative examples, evaluations were made on the basis of evaluation conditions described below about rubber samples each yielded by heating and vulcanizing each rubber composition at 150° C. for 30 minutes.
  • (1) Wet Performance (Wet Gripping Performance)
  • A viscoelasticity tester manufactured by Toyo Seiki Seisaku-sho, Ltd. is used to measure the loss tangent tan δ of one of the samples of each of the above-mentioned examples at a frequency of 10 Hz, a static strain of 10%, a dynamic strain of 1% and a temperature of 0° C. About each of the examples, the measured value is evaluated as an index relative to the value of Comparative Example 1, this value being regarded as 100. It is meant that as the resultant numerical value is larger, the rubber composition is better in wet performance.
  • (2) Exothermic Property (Low Exothermicity)
  • A viscoelasticity tester manufactured by Toyo Seiki Seisaku-sho, Ltd. is used to measure the loss tangent tan δ of one of the samples of each of the above-mentioned examples at a frequency of 10 Hz, a static strain of 10%, a dynamic strain of 1% and a temperature of 60° C. About each of the examples, the measured value is evaluated as an index relative to the value of Comparative Example 1, this value being regarded as 100. It is meant that as the resultant numerical value is smaller, the rubber composition is better in low exothermicity.
  • (3) Abrasion Resistance
  • A Lambourn abrasion tester manufactured by Iwamoto Seisaku-sho Co., Ltd. is used to measure the abrasion loss of one of the samples of each of the above-mentioned examples at a load of 40 N, and a slip ratio of 30% in accordance with JIS K6264. The result is represented as the inverse number of an index relative to the value of Comparative Example 1, this value being regarded as 100. It is demonstrated that as the resultant numerical value is larger, the rubber composition is better in abrasion resistance.
  • (Preparation of Each Rubber Composition)
  • In a blend formulation in Table 1, a rubber composition of each of Examples 1 to 8 and Comparative Examples 1 to 5 was formulated, and then kneaded by using an ordinary Banbury mixer to prepare a rubber composition. The blending agents shown in Table 1 are as follows (in Table 1, the blend amount of each of the blending agents is represented as a numerical value (in the unit of parts by mass) that is relative to 100 parts by mass of rubber components).
  • a) Thermoplastic Elastomers:
  • Thermoplastic elastomer 1: “S.O.E. 51605” manufactured by Asahi Kasei Corporation (styrene-(hydrogenated SB)-styrene block copolymer; tan δ peak value=1.38, and peak temperature=18° C.)
  • Thermoplastic elastomer 2: “HYBRAR 7125” manufactured by Kuraray Co., Ltd. (styrene-(hydrogenated IP)-styrene block copolymer; tan δ peak value=1.84, and peak temperature=−6° C.)
  • Thermoplastic elastomer 3: “S.O.E. 51611” manufactured by Asahi Kasei Corporation (styrene-(hydrogenated SB)-styrene block copolymer; tan δ peak value=0.83, and peak temperature=9° C.)
  • Thermoplastic elastomer 4: “Tuftec H1062” manufactured by Asahi Kasei Corporation (hydrogenated SEBS; tan δ peak value=0.86, and peak temperature=−47° C.)
  • Thermoplastic elastomer 5 (modified thermoplastic elastomer): Into a pressure-resistant vessel equipped with a stirrer were added 800 g of cyclohexane, 38 g of sufficiently dehydrated styrene, and 7.7 g of a sec-butyl lithium solution (10% by weight) in cyclohexane to conduct polymerization reaction at 50° C. for 1 hour. Next, thereto was added 127 g of a mixture of styrene and butadiene (molar ratio of styrene:butadiene=3:4) to conduct polymerization reaction for 1 hour. Thereto was further added 38 g of styrene to conduct polymerization reaction for 1 hour. Thereafter, thereto was added 2.5 g of chlorotriethoxysilane. Finally, thereto was added methanol to stop the reaction to synthesize a styrene-(styrene/butadiene)-styrene type block copolymer having, at a single terminal of the molecule thereof, an ethoxysilyl group. The reaction solution was distilled under reduced pressure to remove the solvent to produce a thermoplastic elastomer 5. The number-average molecular weight thereof was 163,000, which was analyzed through a GPC (gel permeation chromatograph), and the styrene content therein was 60%. The tan δ peak value thereof was 1.23, and the peak temperature was 7° C. The used GPC was a GPC “HPC-8020” manufactured by Tosoh Corporation, and tetrahydrofuran was used as a solvent. The measurement of the molecular weight was made in terms of a standard polystyrene.
  • b) Rubber Components
  • Terminal-non-modified SBR: “VSL 5025-0HM”, manufactured by Lanxess AG
  • Terminal-modified SBR: “HPR 350”, manufactured by JSR Corporation
  • NR: “RSS #3”
  • BR: “BR 150B”, manufactured by Ube Industries, Ltd.;
  • c) Silica: “NIPSILAQ” (manufactured by Tosoh Silica Corporation)
    d) Carbon black: “DIABLACK N341” (manufactured by Mitsubishi Chemical Corporation)
    e) Silane coupling agent: “Si 69” (manufactured by Evonik Degussa GmbH)
    f) Oil: “PROCESS NC140”, manufactured by Japan Energy Corporation
  • g) Tackifying Resins:
  • Tackifying Resin 1: “FTR 6125” manufactured by Mitsui Chemicals, Inc. (copolymer made from a styrene based monomer and an aliphatic monomer; softening point: 125° C., and molecular weight: 1950)
  • Tackifying Resin 2: “FMR 0150” manufactured by Mitsui Chemicals, Inc. (copolymer made from a styrene based monomer and indene; softening point: 145° C., and molecular weight: 1190)
  • Tackifying Resin 3: “NITTO RESING90” manufactured by Nitto Chemical Co., Ltd. (coumarone resin; softening point: 90° C., and molecular weight: 770)
  • h) Zinc flower: “Zinc flower No. 1” (manufactured by Mitsui Mining & Smelting Co., Ltd.)
    i) Antiaging agent: “ANTIGEN 6C”, manufactured by Sumitomo Chemical Co., Ltd.
    j) Stearic acid: “LUNAC S-20” (manufactured by Kao Corporation)
    k) Wax: “OZOACE 0355” (manufactured by Nippon Seiro Co., Ltd.)
    l) Sulfur: “5%-Oil-blended powdery sulfur” (manufactured by Tsurumi Chemical Industry Co., Ltd.)
    m) Vulcanization accelerators:
  • Vulcanization accelerator 1: “SOXINOL CZ” (manufactured by Sumitomo Chemical Co., Ltd.), and
  • Vulcanization accelerator 2: “NOCCELER D”, manufactured by Ouchi Shinko Chemical Industrial Co., Ltd.; and
  • n) Liquid rubbers:
  • Liquid rubber 1: “LBR 307” manufactured by Kuraray Co., Ltd. (liquid polybutadiene; Tg: −95° C.), and
  • Liquid rubber 2: “LIR 30” manufactured by Kuraray Co., Ltd. (liquid polyisoprene; Tg: −63° C.)
  • TABLE 1
    Comparative Comparative Comparative Comparative Comparative
    Example 1 Example 2 Example 3 Example 4 Example 5 Example 1
    Thermoplastic 10 5
    elastomer 1
    Thermoplastic
    elastomer 2
    Thermoplastic 10
    elastomer 3
    Thermoplastic 10
    elastomer 4
    Thermoplastic
    elastomer 5
    SBR (1) 70 70
    (terminal-non-modified)
    SBR (2) 70 70 70 70
    (terminal-modified)
    NR
    BR 30 30 30 30 30 30
    Silica 70 70 70 70 70 70
    Coupling agent 7 7 7 7 7 7
    Carbon black 10 10 10 10 10 10
    Silane coupling agent 7 7 7 7 7 7
    Oil 20 20 20 20 20 20
    Liquid rubber 1
    Liquid rubber 2
    Resin
    Zinc flower 3.0 3.0 3.0 3.0 3.0 3.0
    Antiaging agent 2.0 2.0 2.0 2.0 2.0 2.0
    Stearic acid 2.0 2.0 2.0 2.0 2.0 2.0
    Wax 2.0 2.0 2.0 2.0 2.0 2.0
    Sulfur 1.5 1.5 1.5 1.5 1.5 1.5
    Vulcanization 1.8 1.8 1.8 1.8 1.8 1.8
    accelerator 1
    Vulcanization 2.0 2.0 2.0 2.0 2.0 2.0
    accelerator 2
    Wet gripping performance 100 90 120 92 88 104
    Exothermic property 100 75 108 84 77 80
    Abrasion resistance 100 110 98 96 92 110
    Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8
    Thermoplastic 10
    elastomer 1
    Thermoplastic 10 10 10 10 10
    elastomer 2
    Thermoplastic
    elastomer 3
    Thermoplastic
    elastomer 4
    Thermoplastic 10
    elastomer 5
    SBR (1)
    (terminal-non-modified)
    SBR (2) 70 70 70 70 70 70 70
    (terminal-modified)
    NR 15
    BR 30 30 30 30 30 30 15
    Silica 70 70 70 70 70 70 70
    Coupling agent 7 7 7 7 7 7 7
    Carbon black 10 10 10 10 10 10 10
    Silane coupling agent 7 7 7 7 7 7 7.0
    Oil 20 20 20 20
    Liquid rubber 1 20 20
    Liquid rubber 2 20
    Resin 10
    Zinc flower 3.0 3.0 3.0 3.0 3.0 3.0 3.0
    Antiaging agent 2.0 2.0 2.0 2.0 2.0 2.0 2.0
    Stearic acid 2.0 2.0 2.0 2.0 2.0 2.0 2.0
    Wax 2.0 2.0 2.0 2.0 2.0 2.0 2.0
    Sulfur 1.5 1.5 1.5 1.5 1.5 1.5 1.5
    Vulcanization 1.8 1.8 1.8 1.8 1.8 1.8 1.8
    accelerator 1
    Vulcanization 2.0 2.0 2.0 2.0 2.0 2.0 2.0
    accelerator 2
    Wet gripping performance 114 118 122 115 116 128 120
    Exothermic property 83 82 76 80 80 88 83
    Abrasion resistance 108 108 112 126 124 112 124
  • From the results in Table 1, it is understood that the vulcanized rubber of the rubber composition of each of Examples 1 to 8 is improved in wet performance, fatigue resistance and tearing force resistance.

Claims (5)

What is claimed is:
1. A rubber composition, comprising a terminal-modified polystyrene butadiene rubber in an amount of 10 to 80 parts by mass when the entire amount of rubber components in the composition is regarded as 100 parts by mass; and a thermoplastic elastomer in an amount of 1 to 20 parts by mass for the 100 parts by mass of the rubber components; the thermoplastic elastomer showing a tan δ peak value in the range of −20 to 20° C. in a dynamic viscoelasticity test (temperature dependency measurement at 10 Hz) of the elastomer according to JIS K6394, and the peak value being 1 or more.
2. The rubber composition according to claim 1, further comprising, as one or more of the rubber components, at least one of natural rubber and polybutadiene rubber.
3. The rubber composition according to claim 1, further comprising a filler, and the thermoplastic elastomer being a thermoplastic elastomer having a functional group that can react with or interact with the filler.
4. The rubber composition according to claim 1, further comprising a tackifying resin having a softening point of 90 to 160° C. and a number-average molecular weight of 500 to 3000 in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass.
5. The rubber composition according to claim 1, further comprising a liquid rubber having a Tg of −40° C. or lower in an amount of 1 to 40 parts by mass for the entire amount of the rubber components, the entire amount being regarded as the 100 parts by mass.
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